Mill View System
The Mill View System software package is an analytical tool that uses colorful graphic displays to highlight specific mill process parameters and allows for the examination of setup data for each billet rolled. Mill operators and rollers can assess causes of cobbles, improve mill setup practices (compare existing setups to actual), and predict equipment deterioration.
Mill Control System
New speed control concept for rolling of long products
A PLC-based rolling mill speed control system provides high-performance mill setup and control functions for the processing of long products in a continuous rolling mill.
The Mill Control System comes complete with a real-time PC-based simulator for preliminary mill tune up and operator training. Powerful Windows NT-based HMI screens with built-in help menus help the operator be more effective in processing tonnage.
Sample of technical details and options:
The basic system includes the following:
1. Quantum (Modicon) PLC including the IEC1131 programming software with extensive use of engineered function blocks and online documentation.
2.Windows NT workstation and dual screen displays for setup, control, monitoring and maintenance. The system is designed to control mill stands via any of the popular networks or through hardwired I/Os, (including Profibus(R), Modbus Plus(R), Devicenet(R), Interbus-S(R)).
The Mill Control System will typically interface to the mill drives through a high-speed network.
When installed in an older mill, The Mill Control System can be interfaced to analog drives.
SESA Training Mill Simulator
Practice rolling theory, mill setup and hands-on mill control
A real-time mill simulator helps train new operators and upgrade the skills of your current operators in understanding the basic principles of mill setup and controls. It provides a generic rolling operating environment through real HMIs with a control console and tests their operating skills to running a cobble-free mill. Through learning and comprehensive testing, the operators will gain the knowledge required to achieve high production levels and minimize cobble rate.
The operator is trained step-by-step on the principles of proper mill setup.
The setup environment is generic and the emphasis is on the process (not what the screens look like).
Dynamic rolling is simulated. The operator downloads the mill setup, starts the mill and initiates charging billets from the reheat furnace. The simulator displays motor speeds and currents as the billet threads through the mill. The operator applies cascade speed trims to any of the stands and observes the changes to motor loads due to push-pull interstand forces. He is forced to react to events as if encountered in the normal operation of a mill.
Help/teach feature assists the operator with basic theory of rolling and how it is applied in practice. Key topics covered are: mill setup, starting the mill, understanding interstand push-pull forces, understanding impact drop compensation, pass reduction and relationship to speed, understanding drives.
The HMI screens provide a generic environment for basic understanding of rolling, suitable for training operators independent of their plant control system. Simulator and HMI screens can be adopted to represent the user mill configuration.
A comprehensive course includes basic rolling theory and hands-on rolling of shapes on SESA lab rolling mill to complement the mill control simulator sessions.
Running real-time models of mechanical and electrical equipment and metallurgical models of bar sections.
Mill Control System
A PLC controller board residing in the PC chassis running a real Mill Control System.
Operator interface screens (2) displaying setup, control and monitoring functions. A separate screen is dedicated to online help and rolling theory training
A flat membrane keyboard, designed to provide the feel of a real operator console, complete with raise and lower push buttons for each stand and additional critical control action push buttons.
Furnace Control System
PLC-based arc furnace regulation and control system with a superimposed powerful HMI station provides an easy to upgrade, yet sophisticated approach to EAF optimization. The overall system is based on the integration of various functional components which can be applied individually to a partial upgrade situation or supplied as a complete system for a new operating environment.